Feed Ratio
Operational setting in weaving and warp preparation controls the rate at which warp yarns are fed relative to the fabric speed. Weaving mills adjust the warp overfeed percentage to control the crimp, density, and bulk of the woven fabric. A higher overfeed delivers more yarn than the taking-up mechanism pulls, creating a fuller, softer fabric with higher thickness and cover.
This parameter is critical for producing specialty fabrics like terry towels or heavy blanketing where volume and absorption are key characteristics.
Tension Control
Tension must be carefully balanced to prevent yarn damage and loom stops. If the warp overfeed percentage is too low, the warp yarns are pulled too tightly, which leads to high tension and frequent breaks. This problem is particularly severe when weaving fine or weak yarns.
Fabric Behavior
High overfeed percentages increase the crimp of the warp yarns, which improves the fabric elasticity in the warp direction. This setting can be used to achieve stretch properties in fabrics without using elastic yarns. This adjustment is standard practice for certain mechanical stretch finishes.
Machine Calibration
Modern high-speed looms use electronic feed rollers to control the warp sheet delivery with high precision. Calibration is checked regularly to ensure the actual delivery matches the set overfeed value. This verification is essential for maintaining consistent fabric weight and appearance.
